Vibration Systems and Methods

ABSTRACT

In one or more embodiments, a vibration system comprises a vibratable plate, a support member surrounding the vibratable plate, and a vibration-inducing member surrounding the support member, wherein the vibration-inducing member is configured to radially expand and contract against the support member so as to produce axial vibration of the vibratable plate. In one embodiment, the vibratable plate has an outer circumference; a tubular member is concentrically disposed about the outer circumference of the plate, and an annular vibration-inducing member is concentrically disposed about the outer circumference of the tubular member. The vibration-inducing member is preferably a piezoelectric ring that is radially expandable and contractable against the wall of the tubular member to cause the plate to vibrate in the axial direction. In another embodiment, an aerosol generating system comprises an piezoelectric ring that is radially expandable and contractable upon actuation thereof; a tubular member disposed within the center hole of the piezoelectric ring, and a circular vibratable aperture plate disposed across the internal lumen of the tubular member. The piezoelectric ring is radially expandable and contractable against the tubular member to cause the aperture plate to vibrate in the axial direction, and a reservoir of liquid is coupled to the tubular member so as to supply the liquid to the vibratable aperture plate and produce an aerosol upon vibration thereof.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.60/684,720, filed May 25, 2005, entitled “Aerosolizer System WithReusable Components And Methods For Making,” the complete disclosure ofwhich is herein incorporated by reference.

BACKGROUND OF THE INVENTION

This invention relates generally to a vibration system that efficientlytransfers radial vibration from a vibration-inducing member to produceaxial vibration in a vibratable member through a support member thatfilters out undesirable vibration. In preferred embodiments, apiezoelectric transducer imparts ultrasonic oscillation to a vibratableplate, particularly a vibrating aperture (orifice) plate of an aerosolgenerator device, wherein the vibrating plate is perforated with holesand is operable in a fluid medium. The invention may also useful in thefield of ultrasonic wave transmission in a fluid medium including, butnot limited to, underwater sonar, depth sonar and obstacle detectingsonar.

Devices wherein a circular aperture plate is vibrated using apiezoelectric transducer in the form of a ring are well-known in theart. For example, in Maehara U.S. Pat. No. 4,605,167, a vibratable platehaving at least one nozzle opening therein is secured to a rigid housingand a piezoelectric ring is secured to the vibratable plate for inducingtherein a displacement to discharge a small quantity of liquid throughthe nozzle opening. In other devices described in the art, a circularvibratable plate is directly bonded to the piezoelectric ring and coversthe central opening in the piezoelectric ring; for example, as describedin Toda U.S. Pat. No. 5,297,734. As other examples, Humberstone et alU.S. Pat. No. 5,518,179, Ross et al U.S. Pat. No. 5,261,601 and Davisonet al U.S. Pat. No. 6,062,212 describe vibrating devices wherein acircular vibratable plate is mounted over the central opening of a thinannular member, or “washer”, which is bonded to a piezoelectric ring.When actuated, the piezoelectric ring vibrates radially to cause thewasher to operate in a “bending mode” that vibrates the vibratable platein the axial direction. When these types of devices are manufactured thecomponents must be carefully aligned concentrically with each other whenthe vibratable plate is attached to the washer and the washer ispositioned over the opening in the piezoelectric ring.

Installing an ultrasonic transducer directly onto a rigid frame orhousing, such as taught by Maehara, is also problematic. The reason isthat the entire body of the transducer vibrates, with some portionsvibrating at a small amplitude and some portions vibrating at anamplified amplitude. When the transducer is installed on the rigidfixture, the oscillation amplitude is reduced. Another problem withprior art arrangements is that the piezoelectric ring naturally vibratesin 3 directions (i.e., X, Y and Z axes) and transmits such vibration tothe vibrating plate. The vibrations that are transmitted to the plateare superimposed and the contribution of the axial vibration may becanceled or partially canceled out. It is therefore desirable to filterout the undesirable vibration of the piezoelectric element and to useonly vibration in a single direction, e.g. the axial direction. Attemptsto address this problem have included mounting the vibratable plate onresilient retainer members, or “fingers”, e.g. as described in MartensIII et al U.S. Pat. No. 6,450,419; supporting a bimorph-type transduceron rubber O-rings, e.g. as described in Ross et al U.S. Pat. No.5,261,601 and Humberstone et al U.S. Pat. No. 5,518,179; and holding thepiezoelectric ring in place with a grommet, e.g. as described in Helf etal U.S. Pat. No. 6,293,474 and Tomkins et al U.S. Pat. No. 6,382,522.

The above-described devices translate the radial vibration of apiezoelectric ring to axial vibration of a perforate plate to disperse aliquid as an aerosol. In another type of device, the piezoelectrictransducer may be tubular and may expand and contract axially (in thedirection of the central axis of the tube) to move a perforate plate.For example, see Newcombe et al U.S. Pat. No. 5,838,350.

Generally, in a piezoelectric transducer that operates in a fluidmedium, such as those used in aerosolizers, there is a need to separatethe piezoelectric element from the vibratable element so that thevibratable element can be submerged in liquid and the piezoelectricelement can be electrically insulated from the liquid. In some cases,such insulation may be provided by encasing the piezoelectric elementwith elastomer material. Such material, while providing electricalinsulation, also has energy-absorbing characteristics that dampen theoscillation amplitude of the piezoelectric transducer and therefore hasan adverse effect of the efficiency of the device.

There are currently a wide variety of aerosolizers and nebulizers. Ofparticular interest are those which vibrate an aperture plate or otherelement to produce the aerosol. Examples of some of these aerosolizersare described in U.S. Pat. Nos. 5,169,740, 5,938,117, 6,540,154,5,586,550, 5,750,647, 6,467,476, 6,014,970, 6,755,189, 6,814,071,6,554,201, 6,732,944, 6,615,824, 6,845,770, and 6,851,626, each of whichis incorporated herein by reference in its entirety. One issue withaerosolizers (especially those used for medical applications usinghighly corrosive liquids) is contamination and corrosion of parts.Certain parts of the aerosolizer that are exposed to liquids may need tobe washed or disposed of in order to keep the aerosolizer in goodworking order. Many of these parts are difficult to clean and, sincepiezoelectric transducers and their associated electronics can berelatively expensive, making them disposable may not be economicallyfeasible. Therefore, it may be desirable to make certain aerosolizercomponents removable or replaceable.

BRIEF SUMMARY OF THE INVENTION

One or more embodiments of the present invention are directed to avibration system that efficiently transfers radial vibration from avibration-inducing member to produce axial vibration in a vibratablemember through a support member that filters out undesirable vibration.In one particular arrangement, the vibration-inducing member may be anannular piezoelectric transducer having a central opening, thevibratable member may be a thin circular plate and the support membermay have a circular cross-section for holding the circular plate;however, the components may also possibly have other shapes. In otherarrangements, the vibration-inducing member is separable from the otherstructures so that it may be reused for other applications. In addition,other arrangements of the present invention effectively isolate thevibration-inducing member from contact with liquids and is thereforeparticularly adapted for operation in a fluid medium, e.g. in anaerosolizer environment. Still further, the present invention provides amethod for self-aligning the components of a vibration system comprisinga piezoelectric ring and a circular vibratable plate so as makemanufacture of the system simple and inexpensive.

In one or more embodiments, the vibration system of the presentinvention comprises a thin circular vibratable plate, a tubular memberholding the vibratable plate and a piezoelectric ring coupled to thetubular member. The vibratable plate may be concentrically disposedwithin the lumen of a thin-walled tubular member; and a piezoelectricring may be concentrically positioned about the outer circumference ofthe tubular member at the location of the vibratable plate. Thepiezoelectric ring is expandable and contractable in the radialdirection, which in turn causes the walls of the tubular member toexpand and contract in the radial direction. This movement of thetubular member walls expands and contracts the outer circumference ofthe plate causing its middle region to oscillate (i.e. vibrate) in theaxial direction. Since the outer circumference of the vibratable plateof the present invention is positioned within the central opening of thepiezoelectric ring in alignment with its central plane, in contrast toprior systems wherein a surface of the vibratable plate (or concentricwasher around the plate) is secured at the surface of the piezoelectricring across the central opening of the piezoelectric ring, the radialload produced by the piezoelectric ring is more symmetrically applied tothe vibratable plate of the present invention.

In one embodiment, the vibratable plate may be an aperture plate thatincludes a plurality of tapered apertures and is preferably dome-shaped.The aperture plate may be coupled to a mounting structure disposedwithin the lumen of the tubular member that holds the aperture plateperpendicular to the central axis of the tubular member.

In another embodiment, the tubular member may be fabricated from acorrosive-resistant metallic material, e.g. a palladium/nickel alloy orstainless steel, and have flexible thin walls, e.g. less than 0.5 mm inthickness. In other embodiments, the tubular member may comprise aplastic material, and may include at least one resilient segment, e.g.an elastomer, disposed therein that allows the tubular member to becompressed and expanded by the piezoelectric ring. In anotherembodiment, the piezoelectric ring may be removable from the tubularmember and re-used for other applications. For example, the tubularmember may be tapered to form a “taper lock” wherein the piezoelectricring is press-fitted with the tubular member. In a still furtherembodiment, the piezoelectric ring may be permanently bonded to thetubular member to form an integral unit.

In one embodiment, a tubular member containing an aperture plate may beoperably coupled to a reservoir of liquid, or the reservoir may be anintegral part of the tubular member, so that liquid is supplied to theaperture plate within the tubular member. In this way, when the apertureplate is vibrated in accordance with the invention, liquid droplets areejected from the aperture plate in the form of an aerosol. Optionally, aring may be disposed about the outer periphery of the piezoelectric ringto assist in vibrating the aperture plate at its resonant frequency. Inembodiments wherein the tubular member and the piezoelectric ring arenot integrated with the reservoir, O-rings or other seals may beprovided between the reservoir and the tubular member to serve asliquid-tight seals that prevent contamination of the piezoelectric ring,and also provide damping the piezoelectric ring and the aerosolizerhousing, thereby increasing the efficiency of the system. In anotherembodiment, the tubular member may be “press-fitted” (i.e. form an“interference fit”) with a discharge opening of the reservoir.

In one embodiment of the invention, the reservoir and the tubular membercontaining the aperture plate may be integrated as a single unit, andthe piezoelectric ring may be slid over the reservoir of the aerosolizerto form a press-fit with the tubular member. In this way, thepiezoelectric ring may be removed without potential contamination fromsubstances within the reservoir or tubular member, or from aerosolproduced by the aperture plate. In another embodiment, the piezoelectricring and the tubular member may be bonded together as an integral unit.

The vibration system of the present invention may be incorporated into avariety of products and may be connected to power supplies, electronicsto vibrate the vibration-inducing member, and the like. In oneembodiment, the vibration system of the present invention is connectedto a power supply using a first wire that makes electrical contact witha first surface of the piezoelectric ring and a second wire that makeselectrical contact with a second surface of the vibration-inducingmember. These wires may be located in grooves surrounding the outersurface of the housing in which the vibration system is located so thatthey are isolated from liquids in the reservoir and within the tubularmember of the vibration system.

Examples of products that may employ the vibration system of the presentinvention include ventilators, continuous positive airway pressure(CPAP) systems, hand-held nebulizers and the like, as well as devicesthat utilize ultrasonic wave transmission in a fluid medium, such as,for example, various sonar devices. As one example, a ventilator circuitmay comprise a length of tubing, and the vibration system of the presentinvention may be operably coupled to the tubing to introduce aerosolgenerated by the vibration system into the ventilator circuit. Asanother example, an aerosolizer may be constructed of a housing having amouthpiece and the vibration system of the invention may be disposed inthe housing so that liquid droplets produced by the vibrating apertureplate are ejected through the mouthpiece and into the respiratory systemof the user.

One embodiment of the invention provides an exemplary method for makinga vibration system comprising the steps of inserting a vibratable plateinto a support structure that surrounds the plate; surrounding thesupport structure including vibratable plate with a vibration-inducingmember that is configured to expand and contract radially; and actuatingthe vibration-inducing member to produce radial expansion andcontraction against the support member to cause axial vibration of thevibratable plate.

In one particular embodiment, a method of making a vibration systemcomprises the steps of providing a tubular member with a lengthwiselumen, securing a circular vibratable plate within the lumen so that thevibratable plate is perpendicular to the central axis of the tubularmember; providing a piezoelectric ring having a center opening;positioning the tubular member within the center opening of thepiezoelectric ring so that outer circumference of the tubular member isin contact with the inner circumference of the opening and thevibration-inducing member surrounds the vibratable plate within thetubular member; and securing the vibration-inducing member to thetubular member.

In another embodiment, a method of vibrating a plate comprises the stepsof inserting a vibratable plate in a support structure that surroundsthe entire periphery of the plate, inserting the support structureincluding vibratable plate into the central opening of avibration-inducing member that is configured to expand and contractradially, and actuating the vibration-inducing member to produce radialexpansion and contraction against the support member that causes axialvibration of the vibratable plate.

In another embodiment, a method of treating a patient is provided, whichcomprises the steps of providing a vibration system comprising acircular vibratable aperture plate having an outer circumference, atubular member concentrically disposed about the outer circumference ofthe vibratable plate, wherein the tubular member has an outercircumference, and an annular vibration-inducing member concentricallydisposed about the outer circumference of the tubular member, whereinthe vibration-inducing member is radially expandable and contractable tocause the aperture plate to vibrate in the axial direction; supplying aliquid medicament to the aperture plate via the tubular member;actuating the vibration-inducing member to vibrate the aperture plateand aerosolize the liquid medicament; and supplying the aerosol to apatient's respiratory system.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 a and 1 b are exploded perspective views of a vibration systemof the invention.

FIG. 2 is a partial cross-sectional view of the assembled vibrationsystem of FIGS. 1 a and 1 b.

FIGS. 3 a and 3 b are cross-sectional side views of the vibration systemof FIG. 2.

FIG. 4 a is a cross-sectional side view of one embodiment of anaerosolizer according to the invention.

FIG. 4 b is a partial cross-sectional view of the aerosolizer shown inFIG. 4 a.

FIG. 4 c is a perspective view of the aerosolizer shown in FIG. 4 a.

FIG. 4 d is a cross-sectional side view of another embodiment of anaerosolizer according to the invention.

FIG. 5 a is a perspective view of another embodiment of a vibrationsystem according to the invention.

FIG. 5 b is a partial cross-sectional view of the vibration system shownin FIG. 5 a

FIG. 6 is a perspective view of another embodiment of a vibration systemaccording to the invention.

FIG. 7 a is a perspective view of another embodiment of an aerosolizeraccording to the invention.

FIG. 7 b is a cross-sectional side view of the aerosolizer of FIG. 7 a.

FIG. 8 is a cross-sectional side view of another embodiment of anaerosolizer system according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

All publications, patents and patent applications cited herein, whethersupra or infra, are hereby incorporated by reference in their entiretyto the same extent as if each individual publication, patent or patentapplication was specifically and individually indicated to beincorporated by reference.

It must be noted that, as used in this specification and the appendedclaims, the singular forms “a,” “an” and “the” include the plural unlessthe content clearly dictates otherwise.

Reference herein to “one embodiment”, “one version” or “one aspect”shall include one or more such embodiments, versions or aspects, unlessotherwise clear from the context.

In one or more embodiments, the vibration system of the presentinvention comprises a vibratable plate, a support member surrounding thevibratable plate, and a vibration-inducing member surrounding thesupport member, wherein the vibration-inducing member is configured toradially expand and contract against the support member so as to produceaxial vibration of the vibratable plate. The following detaileddescription is directed to one preferred embodiment of the inventionwherein the vibratable plate is circular, the support member has acircular cross-section, e.g. a tubular member (cylindrical or tapered),into which the circular vibratable plate is disposed, and thevibration-inducing member is an annular disc having a central opening,i.e. a piezoelectric ring, into which the support member is disposed.However, it should be understood that the invention is not limited tothis embodiment.

The tubular member may be manufactured from a corrosion-resistant metal,for example, stainless steel (preferably grades 316, 303 or 416),titanium, or a C-276 chrome/nickel alloy (e.g. Hastelloy® C-276). Thetubular member preferably has relatively thin walls that can beeffectively deflected by the piezoelectric ring. In one embodiment, thethickness of the walls of the tubular member is in the range of 0.1 mmto 0.5 mm, preferably about 0.25 mm. In one embodiment, the tubularmember may have a shelf structure disposed around its inner surface towhich the periphery of the vibratable plate may be bonded so that itextends across the internal lumen of the tubular member perpendicular toits central axis.

Various piezoelectric rings known in the art may be suitable for use asthe annular vibration-inducing member of the present invention. In oneembodiment, the piezoelectric ring may comprise any material exhibitingpiezoelectric properties, for example, a piezoelectric ceramic materialsuch as lead zirconate titanate (PZT) or lead metaniobate (PN) and maytake the shape of a disc of substantially constant thickness with acentral hole. Such piezoelectric rings are commercially available, e.g.from American Piezo Ceramics, Inc. (APC), Mackeyville, Pa., and fromMorgan Electro Ceramics (MEC), Fairfield, N.J. The piezoelectric ringmay be supplied with an alternating electric current at the selectedfrequency from a power source; for example, the piezoelectric ring maybe electrically connected by wires to a controller that contains theelectronics necessary to control the vibration of the piezoelectricring.

In accordance with the invention, the tubular member is positionedwithin the center opening of the piezoelectric ring. When actuated bythe alternating electrical fields from the controller, the piezoelectricring expands and contracts in the radial direction against the walls oftubular member in the vicinity of the vibratable plate. This movement ofthe tubular member walls expands and contracts the periphery of thevibratable plate, thereby forcing the center of the vibratable plate tooscillate in the axial direction, i.e. to move up and down along thecentral axis of the tubular member. Although the piezoelectric ring mayalso vibrate in the axial direction and may create a transverse surfacewave, only the radial vibration can transmitted to the vibratable plateby the tubular member. In this way, the superposition of conflictingvibration modes is eliminated and efficient translation of electricalenergy to mechanical movement is accomplished. The practice of thepresent invention also allows the vibration system to be installeddirectly to a rigid body, such as the frame or housing of anaerosolizer, nebulizer or other device, without having the vibrationtransfer to the entire body. This is mainly because the ends of thetubular member do not vibrate and therefore may be used to install thevibration system to the rigid body.

The invention may be particularly useful when the tubular member isemployed to hold an annular aperture plate or other structure having aplurality of apertures. When a liquid is applied to one side of theaperture plate through the tubular member and the piezoelectric ring isactuated, the aperture plate oscillates in a manner that causes liquiddroplets to be ejected from the apertures. The resultant aerosol maythen be dispensed out the open end of the tubular member.

A particularly useful type of aperture plate is one having taperedapertures that taper from the surface contacting the liquid to thesurface where the droplets are ejected. Also, in some embodiments, theaperture plate may be domed shaped, although the invention is notlimited to only such aperture plates. Preferred aperture plates may havea thickness in the range of 20 to 100 microns. Examples of piezoelectricmaterials and aperture plates that may be used with the invention aredescribed in U.S. Pat. Nos. 6,235,177 and 5,758,637, incorporated hereinby reference. In another embodiment, the piezoelectric ring may bevibrated at a frequency in the range from about 20 Khz to about 500 Khz,for example, about 128 Khz. In another preferred embodiment, thedroplets may have a size suitable for use in pharmaceutics, for example,in the range from about 3 micrometers (μm) to about 6 μm, and the liquidmay be aerosolized at a rate in the range from about 5-20microliters/second.

Referring now to FIGS. 1 a, 1 b and 2, one embodiment of the presentinvention will be described. Vibration system 10 comprises vibratableplate 101, tubular member 102 and piezoelectric ring 103. Tubular member102 has an outer circumference 104 and an inner circumference 105, whichtogether define a relatively thin cylindrical wall, preferably having athickness in the range from about 0.1 mm to 0.5 mm. The hollow center(lumen) of tubular member 102 terminates in openings 106 and 107 atopposing ends thereof. Mounting structure 111 comprises a circular ridgethat projects perpendicularly from inner circumference 105 into thelumen of tubular member 102 at a location, preferably a centrallocation, between openings 106 and 107. Piezoelectric ring 103 comprisesan annular disc of piezoelectric material having a center hole 108 witha circumference 112 approximately equal to the outer circumference 104of tubular member 102. Vibratable plate 101 comprises circular outerflange 109 surrounding a thin circular vibratable center portion 110.

In one method of making vibration system 10, metallic tubular member 102may first be provided with mounting structure 111 by bonding a ridge ofmetal around inner circumference 105 at a location equidistant from ends106 and 107. Vibratable plate 101 may then be concentrically disposedwithin the lumen of tubular member 102 with the lower surface ofcircular flange 109 positioned over the upper surface of mountingstructure 111 and with the outer periphery of vibratable plate 101abutting inner circumference 105. Outer flange 109 of vibratable plate101 may be secured onto mounting structure 111 using a suitable joiningprocedure, e.g. a metallurgical process such as brazing, welding,soldering or the like, or a chemical bonding process such as adhesivebonding.

In one preferred embodiment, a brazing ring of a suitablecorrosion-resistant brazing filler material, e.g. a mixture of 70% goldand 30% copper, may be placed between the upper surface of mountingstructure 111 and outer flange 109 of vibratable plate 101. The entireassembly of tubular member 102, vibratable plate 101 and brazing ringmay be held in place by a weight placed on top of vibratable plate 101.The assembly may be placed in an oven and heated to a temperaturesufficient to melt the brazing 1 and permanently join the surfacestogether in a conventional brazing procedure. In another embodiment,vibratable plate 101 may be soldered onto mounting structure 111 usingsoldering materials, such as a tin/lead soldering material; however,this method may not be suitable if the assembly is to be exposed toacidic pharmaceutical preparations. In another embodiment, vibratableplate 101 may be secured onto mounting structure 111 by ultrasonic orlaser welding.

Once vibratable plate 101 is secured across the lumen of tubular member102, tubular member 102 may be positioned within center hole 108 ofpiezoelectric ring 103. In one embodiment, tubular member 102 may beplaced in a fixture that holds tubular member 102 upright, andpiezoelectric ring 103 may be slid lengthwise down tubular member 102until piezoelectric ring 103 surrounds the outer circumference 104 at alocation directly corresponding to the location of mounting structure111 and vibratable plate 101 on inner circumference 105 of tubularmember 102. Outer circumference 104 of tubular member 102 andcircumference 112 of center hole 108 in piezoelectric ring 103 may thenbe bonded together, e.g. by depositing a suitable liquid adhesive aroundthe juncture of circumference 104 and circumference 112 and curing theadhesive, e.g. with UV light. The adhesive used should be capable ofefficiently transferring vibration from the piezoelectric ring 103 totubular member 102. Although ideally the adhesive would have the modulusof elasticity (“Young's Modulus”) of the piezoelectric ring, i.e. about60 GPa (Giga Pascal), to achieve the ultimate transfer of vibration,this is not possible for any adhesive. Most structural adhesives (suchas epoxy) have a modulus of elasticity of plastic material, which may beabout 2 GPa, and should be suitable for the present invention if curedto approximately that stiffness. As examples of suitable adhesives,mention may be made of various epoxy and anaerobic adhesives, such ascommercially available UV-cured epoxy adhesives sold under the trademarkLoctite.

As previously described, piezoelectric ring 103 is configured toradially expand and contract when alternating electric fields arecommunicated to it via electric lines. For example, as illustrated inFIG. 3 a, piezoelectric ring 103 contracts radially towards its centeropening (direction D) when actuated by a first electric field. Thisradial contraction causes piezoelectric ring 103 to push inward alongouter circumference 104 of tubular member 102 in the vicinity ofmounting structure 111 and thereby pinch the wall of tubular member 102.The constriction of tubular member 102 causes flange 109 to alsoconstrict radially and, as a result, the center portion 110 ofvibratable plate 101 moves axially in direction A. When actuated by asecond electric field, as shown in FIG. 3 b, piezoelectric ring 103expands radially away from its center opening (direction D′), therebyreleasing the inward pressure along circumference 104 of tubular member102. This release of pressure allows flange 109 to expand radially,which causes center portion 110 of aperture plate 101 to move axially indirection A′ to its original position. Continually alternating theelectric fields produces an oscillation (vibration) of center portion110 between the positions shown in FIGS. 3 a and 3 b.

As previously mentioned, the vibration system of the present inventionis particularly useful for aerosolizing liquids. FIGS. 4 a, 4 b and 4 cillustrate an aerosolization system (referred to herein as “aerosolizer40”) in accordance with embodiments of the present invention. The samereference numbers are used in each of the Figures to refer to the samecomponent. Referring now to FIG. 4 a, aerosolizer 40 comprises upperhousing 401, detachable lower housing 405 and vibration system 10 (e.g.,see FIG. 2). Vibration system 10 comprises tubular member 102,piezoelectric ring 103 and aperture plate 101. Upper housing 401comprises reservoir 402 configured to hold a volume of liquid, e.g. aliquid medicament, and a conical portion 403 at the lower end ofreservoir 402 terminating in discharge tube 404 defined by cylindricalwalls 406. Engagement tube 407 defined by cylindrical walls 408 of upperhousing 401 is concentrically disposed around and completely encompassesdischarge tube 404.

Vibration system 10 is adapted to be detachably engaged with upperhousing 401, with the upper section of tubular member 102 of vibrationsystem 10 (i.e., that section of tubular member 102 above piezoelectricring 103) being configured to be press fit within discharge tube 404 andwith piezoelectric ring 103 of vibration system 10 being configured tobe press fit with engagement tube 407. When assembled, the upper sectionof tubular member 102 of piezoelectric ring 103 is fully encompassed bydischarge tube 404 and the top surface of piezoelectric ring 103 abutsthe lower end of discharge tube 404. This press fit mating of tubularmember 102 and discharge tube 404 forms a liquid-tight seal thatprevents liquid discharged from reservoir 402 into discharge tube 404from coming in contact with piezoelectric ring 103.

Lower housing 405 comprises receiving tube 411 defined by cylindricalwalls 412, annular flange 413 concentrically disposed around the base ofreceiving tube 411 and aerosol chamber 414 defined by cylindrical walls415. Lower housing 405 may be adapted to be detachably engaged withvibration system 10 and upper housing 401, with the lower section oftubular member 102 of vibration system 10 (i.e., that section of tubularmember 102 below piezoelectric ring 103) being configured to be pressfit within receiving tube 411 and with annular flange 413 beingconfigured to be press fit within engagement tube 407. When assembled,the lower section of tubular member 102 is fully encompassed byreceiving tube 411 and forms a passageway directly into aerosol chamber414. The bottom surface of piezoelectric ring 103 abuts the upper end ofreceiving tube 411 to securely hold vibration system 10 withinengagement tube 407.

Referring now to FIGS. 4 b and 4 c, piezoelectric ring 103 may besupplied with an electric current by wires 416 and 417 from batteries oranother power source (not shown). Each of wires 416 and 417 may beshaped in a “c-clip” arrangement and respectively nestled into grooves418 and 419 cut around the periphery of walls 415 of upper housing 401.Terminal end 420 of wire 416 may enter engagement tube 407 throughopening 422 in wall 415 and make electrical contact with the uppersurface of piezoelectric ring 103. Terminal end 421 of wire 417 mayenter engagement tube 407 through hole 423 in wall 415 of upper housing401 and make electrical contact with the lower surface of piezoelectricring 103.

Center portion 110 of aperture plate 101 may be dome-shaped in geometry,although other shapes may be used. Also, center portion 110 may includeapertures that taper from the rear side (facing reservoir 402) to thefront side. When aerosolizer 40 is placed in a generally verticalorientation, the liquid from reservoir 402 may be delivered to and reston the rear side of center portion 110 by force of gravity.Piezoelectric ring 103 is configured to radially expand and contractwhen actuated by alternating electric fields supplied by wires 416 and417. In so doing, the wall of tubular member 102 also constricts andexpands. In this way, center portion 110 vibrates axially so as to ejectliquid droplets from its front side and out the opening in aerosolchamber 414.

One advantage of using vibration system 10 is that aerosolizer 40 may beconstructed so that vibration system 10 is removable from upper housing401 and lower housing 405. In this way, vibration system 10 (whichcontains relatively expensive piezoelectric ring 103) may be reused inother applications. Upper housing 401 and lower housing 405, which maybe able to be produced relatively inexpensively, may be discarded afteruse. Another advantage of using vibration system 10 is that the ends oftubular member 102 may be connected directly to rigid bodies, such aswall 406 of upper housing 401 and wall 412 of lower housing 405, withoutaffecting the oscillating amplitude of aperture plate 110. This enablesaerosolizer 40 to more efficiently produce liquid droplets.

Referring now to FIG. 4 d, aerosolizer 40′ is similar to aerosolizer 40and comprises upper housing 401′ containing reservoir 402′, detachablelower housing 405′ containing aerosol chamber 414′, and vibration system10′, which comprises tubular member 102′, piezoelectric ring 103′ andaperture plate center portion 110′. However, in aerosolizer 40′, theupper section of tubular member 102′ is not press fit into dischargetube 404′ (as shown in FIG. 4 a), but rather O-rings 420 may bepositioned to fill a gap between the upper section of tubular member102′ and discharge tube 404′ of housing 401′. In this way, aliquid-tight seal is formed that prevents liquid from reservoir 402′from contacting piezoelectric ring 103′. Similarly, O-rings 421 may bepositioned to fill a gap between the lower section of tubular member102′ and receiving tube 411′ of lower housing 405′ to form aliquid-tight seal that prevents aerosol produced from aperture platecenter portion 110′ from contacting piezoelectric ring 103′.Accordingly, piezoelectric ring 103′ may be protected from contaminationthat may prevent it from being re-usable after removal from aerosolizer40′, without the tight dimensions required for a press fit, as describedin connection with aerosolizer 40. Since O-rings 420 and 421 arepositioned on both top and bottom surfaces of piezoelectric ring 103′and serve to suspend piezoelectric ring 103′ from direct contact withupper housing 401′ and lower housing 405′, O-rings 420 and 421 may alsohave a dampening effect that reduces the undesirable transfer ofvibration from piezoelectric ring 103′ to upper housing 401′ and lowerhousing 405′.

Referring now to FIGS. 5 a and 5 b, another embodiment of the presentinvention will be described. Vibration system 50 comprises apiezoelectric ring 502 having a central opening 504. Piezoelectric ring502 may be constructed of a piezoelectric material that radially expandsand contracts when actuated, as previously discussed. Tubular member 506is disposed within opening 504 and is adapted to hold aperture plate 508within its internal lumen 509 using any of the techniques describedherein. Tubular member 506 may be constructed of a rigid material, suchas a hard plastic, metal, ceramic or the like. Tubular member 506 mayoptionally include projections 510 to provide a good mechanical contactwith piezoelectric ring 502. As an alternative, tubular member 506 maybe tapered to assure a good mechanical contact.

Tubular member 506 may include one or more resilient segments 511radially extending from locations on its inner circumference tocorresponding locations on its outer circumference. These segments maybe constructed from an elastomeric material and positioned in variouslocations. Resilient segments 511 permit tubular member 506 to beconstructed of a rigid material (for securely holding aperture plate508) while also permitting tubular member 506 to radially expand andcontract with piezoelectric ring 502. More specifically, as tubularmember 506 is constricted by piezoelectric ring 502, resilient segments511 compress to reduce the diameter of lumen 509. When piezoelectricring 502 radially expands, resilient segments 511 expand to increase thediameter of lumen 509. Hence, the amount of expansion and contractionmay be varied based in part on the size, number and types of resilientmaterials used.

Conveniently, vibration system 50 may be coupled to a reservoir of anaerosolizer (not shown) to permit a liquid to be supplied to apertureplate 508. Also, other liquid delivery systems could be used as well,such as wicking systems, and the like. Alternatively, vibration system50 may be incorporated into other systems, such as nebulizers,ventilators and the like.

FIG. 6 illustrates vibration system 50, as shown in FIGS. 5 a and 5 b,with an outer ring 512 disposed about the outer circumference ofpiezoelectric ring 502, which in turn in disposed around tubular member506. Ring 512 may be employed to adjust the operating frequency ofpiezoelectric ring 502. In many applications, it is desirable to operatepiezoelectric ring 502 at a frequency of about 130 Khz, which is theapproximate resonance frequency of the aperture plate. Whenpiezoelectric ring 502 is constructed from a piezoceramic material, itsfrequency is inversely proportional to its diameter where:

f=(½pir)X√{square root over ((E/p))}

Hence, if the diameter of the piezoelectric ring 502 is made larger toreduce the frequency of the piezoelectric ring, the piezoelectric ring502 may be too large for certain applications. A low operating frequencyof piezoelectric ring 502 may result because the piezoelectric materialis “soft” and heavy. To increase the frequency without increasing thediameter, outer ring 512 (which may be constructed of a stiff andlightweight material, such as silicon nitride) may be added. Thecombination of ring 512 and piezoelectric ring 502 serves to increasethe frequency to the desired range.

Referring to FIGS. 7 a and 7 b, an embodiment of an aerosolizationsystem in accordance with the present invention will be described.System 80 includes an aerosolizer that, for convenience of discussion,includes vibration system 50 having ring 512, as shown in FIG. 6,although it will be appreciated that other vibration systems of theinvention could be used as well. Coupled to (or integrally formed with)tubular member 506 of vibration system 50 is a container 802 for holdinga liquid. Conveniently, a lid 804 may be provided to close container 802after filling it with a liquid. Also coupled to tubular member 506 is anoutlet 806 through which an aerosol produced by aperture plate 508 maybe dispensed. O-rings or gasket seals 805 may be disposed betweencontainer 802 and vibration system 50, and between vibration system 50and outlet 806 to provide adequate sealing and cushioning between thecomponents.

One particular feature of aerosolization system 80 is that piezoelectricring 502 has a large enough inner diameter that it may be slid overoutlet 806 and container 802. In this way, system 80 may be easilyassembled and disassembled to remove piezoelectric ring 502. Further,piezoelectric ring 502 does not come into contact with any liquids andtherefore may be reused with another aerosolization system. Further,container 802, tubular member 506 and aperture plate 508 may beconstructed to be relatively inexpensive so that they may be disposed offollowing use. Also, system 80 may easily be incorporated into othersystems, such as hand-held nebulizers, ventilators and the like.

In operation, container 802 is filled with a liquid and lid 804 is putin place. Piezoelectric ring 502 is slid over container 802 and placedover tubular member 506. An electric current is supplied topiezoelectric ring 502 to cause it to expand and contract. In so doing,liquid that is in contact with aperture plate 508 is ejected as liquiddroplets into outlet 806. Following use, container 802 may be refilled,or may be discarded while saving piezoelectric ring 502.

FIG. 8 illustrates another embodiment of the invention whereinaerosolization system 90 includes tubular member 906 comprising asharpened end 901 and a discharge end 903. As previously described,tubular member 906 also contains an aperture plate (not shown) acrossits internal lumen. Piezoelectric ring 904 is disposed around tubularmember 906. When aerosolization system 90 is not in use, sharpened end901 may have a cover (not shown) that protects it from damage andcontamination. When ready for use, the cover may be removed andsharpened end 901 may be inserted through the membrane top of a vial902, which contains liquid 905 to be aerosolized. Liquid 905 is thendelivered through sharpened end 901 and the lumen of tubular member 906to the aperture plate contained therein. Piezoelectric ring 904 may beactuated to vibrate the aperture plate and thereby aerosolize liquid 905in the manner previously described. The resultant aerosol is thendispensed through discharge end 903. After use, vial 902 may be removedfrom sharpened end 901 and discarded, piezoelectric ring 904 may beremoved from the assembly for re-use, and the remaining assembly may bediscarded.

As previously mentioned, the aerosolizers described herein may beincorporated into other systems. Example of ventilator systems aredescribed, for example, in co-pending U.S. patent application Ser. No.10/828,765, filed Apr. 20, 2004, the complete disclosure of which isherein incorporated by reference. The system described therein isparticularly useful in neo-natal and infant continuous positive pressureairway pressure (CPAP) therapies. Accordingly, an aerosolizer of thepresent invention may be coupled to such a ventilator or CPAP circuit tosupply aerosolized medicament to a patient's respiratory system, e.g.through a patient interface device. When the treatment is finished, theaerosolizer, or certain components thereof, may be removed and re-used,while other components of the system may be discarded.

As another example, the aerosolizer of the present invention may beincorporated in a nebulizer such as described in co-pending U.S. patentapplication Ser. No. 10/833,932, filed Apr. 27, 2004, the completedisclosure of which is herein incorporated by reference. The nebulizercomprises a main housing coupled to an aerosolizer housing, which maycomprise an aerosolization system such as previously described inconnection with aerosolizer 40 shown in FIGS. 4 a, 4 b and 4 c,including a reservoir for holding a liquid medicament that is to beaerosolized and a vibration system according to the present inventionhaving an aperture plate with a plurality of tapered apertures extendingbetween a first surface and a second surface, as described in U.S. Pat.Nos. 5,164,740, 5,586,550, 5,758,637, and 6,085,740, the entire contentsof which are incorporated herein by this reference. The nebulizer mayalso have a mouthpiece coupled to the main housing. At least a portionof the tubular member of the vibration system of the present inventionmay be disposed in the housing so that liquid droplets are ejectedthrough the mouthpiece to permit a patient to inhale the aerosolizedmedicament. The apertures in the aperture plate may be sized to producean aerosol in which about 70% or more of the droplets by weight have asize in the range from about 1 to about 5 micrometers. Following use,the aerosol housing may be removed from the main housing. The liquid maybe refilled, or one or more components may be replaced. For example, thevibration system may be removed and reused with another nebulizer.

One embodiment of the present invention provides a method of treating apatient that exhibits one or more symptoms of infection or otherrespiratory disease or disorder. The method generally comprises thesteps of: providing a vibration system comprising a circular vibratableaperture plate having an outer circumference, a tubular memberconcentrically disposed about the outer circumference of the vibratableplate, wherein the tubular member has an outer circumference, and anannular vibration-inducing member concentrically disposed about theouter circumference of the tubular member, wherein thevibration-inducing member is radially expandable and contractable tocause the aperture plate to vibrate in the axial direction; supplying aliquid medicament to the vibration system; actuating thevibration-inducing member to vibrate the aperture plate and aerosolizethe medicament; and supplying the aerosol to the patient's respiratorysystem.

An aerosol generator in accordance with the present invention has theability to produce a high flow of aerosol relative to the power input.For example, when standard saline solution (2% NaCl) is used, the flowrate of aerosol having a volumetric median diameter (VMD) of 4 micronsmay be 15 microliters/sec and the power consumption of the generator maybe 3 watts.

The invention has now been described in detail for purposes of clarityand understanding. However, it will be appreciated that certain changesand modifications may be practiced within the scope of the appendedclaims.

1. A vibration system comprising: a vibratable plate; a support membersurrounding the vibratable plate, the support member aligning thevibratable plate; and a vibration-inducing member surrounding thesupport member, wherein the vibration-inducing member is configured toradially expand and contract against the support member so as to produceaxial vibration of the vibratable plate.
 2. A vibration system as inclaim 1 wherein the vibratable plate is circular, the support member hasa circular cross-section into which the circular vibratable plate isdisposed, and the vibration-inducing member is an annular disc having acentral opening into which the support member is disposed.
 3. Avibration system as in claim 2 wherein the support member comprises athin-walled tubular member and the vibration-inducing member is apiezoelectric ring.
 4. A vibration system comprising: a circularvibratable plate having an outer circumference; a tubular memberconcentrically disposed about the outer circumference of the plate, thetubular member aligning the circular vibratable plate, wherein thetubular member has an outer circumference; and an annularvibration-inducing member concentrically disposed about the outercircumference of the tubular member, wherein the vibration-inducingmember is radially expandable and contractable against the tubularmember to cause the plate to vibrate in the axial direction.
 5. A systemas in claim 4, wherein the plate includes a plurality of taperedapertures.
 6. A system as in claim 5, wherein the plate has a thicknessin the range from about 20 microns to about 100 microns.
 7. A system asin claim 5, wherein the plate is dome-shaped.
 8. A system as in claim 5,further comprising a reservoir of liquid which is adapted to supply theliquid to the plate.
 9. A system as in claim 5, wherein the tubularmember includes a sharpened end adapted to extract liquid from a vial ofliquid by piercing a membrane covering an opening in said vial.
 10. Asystem as in claim 4, wherein the tubular member has a wall thickness inthe range from about 0.1 mm to about 0.5 mm.
 11. A system as in claim 4,wherein the vibration-inducing member comprises a piezoelectric ring.12. A system as in claim 11, wherein the tubular member includes atleast one resilient segment disposed therein.
 13. A system as in claim12, wherein a ring is disposed around the outer circumference of thepiezoelectric ring to adjust the operating frequency of thepiezoelectric ring.
 14. A system as in claim 4, further comprising amounting structure disposed inside the tubular member, the mountingstructure supporting the circular vibratable plate.
 15. A system as inclaim 4, further comprising a controller for controlling the radialexpansion and contraction of the vibration-inducing member and wiresconnecting the controller to the vibration-inducing member.
 16. A systemas in claim 4 wherein the vibration-inducing member is removable fromthe tubular member.
 17. A method of vibrating a plate comprising thesteps of: inserting a vibratable plate into a support structure thatsurrounds the plate; aligning the vibratable plate using the supportstructure; surrounding the support structure including vibratable platewith a vibration-inducing member that is configured to expand andcontract radially; and actuating the vibration-inducing member toproduce radial expansion and contraction against the support member tocause axial vibration of the vibratable plate.
 18. A method as in claim17, wherein the support member filters out vibration other than axialvibration.
 19. A method for vibrating a plate, comprising: providing aplate having an outer circumference and a tubular member disposed aboutthe outer circumference of the plate, said tubular member having anouter circumference; aligning the plate using the tubular member;providing a piezoelectric ring concentrically positioned about the outercircumference of the tubular member at a location coinciding with theouter circumference of the plate; and radially expanding and contractingthe piezoelectric ring against the tubular member so as to cause theplate to vibrate in the axial direction.
 20. A method as in claim 19,wherein the piezoelectric ring is vibrated at a frequency in the rangefrom about 20 Khz to about 500 Khz.
 21. A method as in claim 19, whereinthe plate includes a plurality of apertures, and further comprisingsupplying a liquid to the plate to aerosolize the liquid as liquiddroplets.
 22. A method as in claim 21, wherein the droplets have a sizein the range from about 3 micrometers to 6 micrometers, and wherein theliquid is aerosolized at a rate of about 5 microliters/second to about20 microliters/second.
 23. A method as in claim 21, further comprisingcoupling a reservoir to the tubular member to supply the liquid to theplate.
 24. An aerosol generating system, comprising: a piezoelectricring having a center hole with an inner circumference adapted to expandand contract radially when electrically activated; at least oneelectrical connection to said piezoelectric ring for electricalactuation thereof a tubular member disposed within the center hole ofthe piezoelectric ring, said tubular member having an outercircumference in contact with the inner circumference of said centerhole and a cylindrical wall defining an internal lumen extending thelength of the tubular member; a circular vibratable aperture plateadapted to aerosolize a liquid upon axial vibration thereof; wherein theaperture plate is disposed across the internal lumen of the tubularmember and in contact with the inner circumference of the lumen at alocation coinciding with the inner circumference of the center hole ofthe piezo electric ring, the tubular member including a mountingstructure for supporting the aperture plate; and a reservoir of liquidcoupled to the tubular member so as to supply liquid to the vibratableaperture plate, whereby radial expansion and contraction of the piezoelectric ring against the wall of the tubular member causes the apertureplate to vibrate in the axial direction and aerosolize the liquid. 25.An aerosol generating system as in claim 24 wherein the vibratable plateis domed-shaped and has a plurality of tapered apertures.
 26. An aerosolgenerating system as in claim 24 wherein the piezoelectric ringcomprises piezoelectric ceramic material.
 27. An aerosol generatingsystem as in claim 24 further comprising a circuit of a ventilatorsystem operably connected to the tubular member so as to dispenseaerosol generated by said vibratable aperture plate into said circuit.28. An aerosol generating system as in claim 24 wherein saidpiezoelectric ring, said tubular member, said vibratable aperture plateand said reservoir are disposed within the housing of a nebulizer havinga mouthpiece.
 29. A method of making a vibration system comprising:aligning a vibratable plate within a support member that surrounds thevibratable plate; and placing around the support member avibration-inducing member configured to radially expand and contractagainst the support member to produce axial vibration of the vibratableplate.
 30. The method of claim 29 wherein the support member is tubularand the aligning includes placing the vibratable plate within thetubular support member and in contact with a mounting structure of thetubular support member.
 31. A method of making a vibration systemcomprising: providing a tubular member having a lengthwise lumen;aligning and securing a circular vibratable plate within the lumen sothat the plate is perpendicular to and covers the lumen of the tubularmember; positioning the tubular member within the center hole of apiezoelectric ring so that the vibratable plate within the lumen of thetubular member is surrounded by the piezoelectric ring in contact withthe outer circumference of the tubular member; and securing thepiezoelectric ring to the tubular member.
 32. A method of making avibration system as in claim 31, further comprising the steps of:bonding a ridge around the inner circumference of the tubular member;positioning the vibratable plate on the ridge; and brazing or weldingthe vibratable plate to the ridge.
 33. A method of making a vibrationsystem as in claim 31 wherein the piezoelectric ring is bonded to thetubular member with an adhesive capable of efficiently transferringvibration from piezoelectric ring to the tubular member.
 34. A method oftreating a patient comprising: providing a vibration system comprising avibratable aperture plate having an outer circumference, providing atubular alignment member concentrically disposed about the outercircumference of the vibratable plate, the tubular alignment memberhaving a mounting structure for holding the vibratable plate, whereinthe tubular alignment member has an outer circumference, and apiezoelectric ring concentrically disposed about the outer circumferenceof the tubular alignment member at a location coinciding with the outercircumference of the aperture plate, supplying a liquid medicament tothe aperture plate; electrically actuating the piezoelectric ring toradially expand and contract the wall of the tubular alignment memberaround the outer circumference of the aperture plate, thereby causingthe aperture plate to vibrate in the axial direction and aerosolize themedicament; and supplying the aerosol to the patient's respiratorysystem.
 35. A method of treating a patient as in claim 34 wherein theaerosol is supplied to the patient's respiratory system through thecircuit of a ventilator or CPAP system.
 36. A method of treating apatient as in claim 34 wherein the aerosol is supplied to the patient'srespiratory system through a nebulizer having a mouthpiece.
 37. Avibration system comprising: a tubular alignment member having acylindrical wall defining a longitudinal lumen; a vibratable platesecured to a mounting structure of the cylindrical wall and disposedacross the lumen; and means for imparting radial vibration to thecylindrical wall of the tubular member so as to produce axial vibrationin the vibratable plate.
 38. A vibration system as in claim 37 whereinthe vibratable plate is an aperture plate having a rear surface incontact with a liquid and a front surface opposed thereto, whereinliquid droplets are ejected from the front surface to form an aerosolupon said axial vibration of the aperture plate.
 39. An aerosolgenerator device comprising: a vibratable plate, an alignment member forreceiving and holding the vibratable plate in a predetermined position,and a vibration-inducing member in communication with the alignmentmember.
 40. The device of claim 39, wherein a portion of the device isdisposable.
 41. The vibration system of claim 1 wherein the vibrationinducing member is in co-planar alignment with a periphery of thevibratable plate.